# 5S Case Study: Lathe Workstation Transformation
> Discover how lean manufacturing and 5S methodology can transform workstation productivity, reduce safety hazards, and eliminate wasted tool search time.

Tags: lean-manufacturing, 5s-methodology, production-engineering, workplace-organization, industrial-safety, continuous-improvement, kpi-metrics
## Slide 1: Lathe Workstation Organisation
* Overview of a 5S Improvement Project and Lean Manufacturing Initiative.
* Focus areas: Sort, Set, Shine, Standardise, and Sustain.

## Slide 2: Problem Identification
* **Tool Clutter:** No designated storage for mixed tools.
* **Safety Hazards:** Metal chips and oil spills in walkways.
* **Wasted Time:** Operators lose 15+ minutes per day searching for tools.
* **Lack of Labeling:** Parts and consumables are unmarked.

## Slide 3: 5S Audit & Root Cause Analysis
* **Baseline Score:** Overall 1.4 / 5.
* **Audit Breakdown:** Sort (1.5), Set (1.0), Shine (2.0), Standardise (1.5), Sustain (1.0).
* **Root Causes:** Lack of training, no shadow boards, no FIFO materials flow, and poor management accountability.

## Slide 4: PDCA Plan and KPIs
* **PDCA Cycle:** Plan (Baseline audit), Do (5S Implementation), Check (Re-audit), Act (Update SOPs).
* **Target Improvements:**
    * Tool search time: 18 min reduced to <2 min.
    * Audit score: 1.4/5 increased to 4.5/5.
    * Safety incidents: 3/mo reduced to 0/mo.
    * Cleaning compliance: 20% to 100%.

## Slide 5: Visual Controls and Outcomes
* **Implemented Controls:** Shadow boards, zone markings, color labels, and Kanban cards.
* **Key Results:** 
    * 89% reduction in tool search time.
    * 40% increase in operator productivity.
    * Zero safety incidents achieved.
    * 100% cleaning compliance.
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